Method for catalytic conversion



May 25, 1943. 1'. P. SIMPSON ETAL METHOD FOR CATALYTIC CONVERSION FiledJuly 22; 1942 2 Sheets-Sheet 1 ELEV/170R INVENTORS 5072, 77 6 andy,.//."

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T. P. SIMPSON ETAL METHOD FOR CATALYTIC CONVERSION Filed July 22, 1942 2Sheets-Sheet 2 H54 7 EXc/MA/GER John W Pay John 4. Crow/e 976 andATTbRNEY Plume May 1 4 UNITED STATES, PATENT OFFICE Thomas 1. Simpson.John W. Payne, and John A. Crowley. In, Woodbnry, N. 1., arllgnors togocony-vacnnm Oil Company. Incorporated, a corporation oi New YorkApplication July 22, 1942, Serial No. 451,858 ie'cnim (cl. 196-52) Thisinvention has to do with chemical reactions which are conducted in thepresence of a contact mass, such as, for example. the catalyticconversion oi hydrocarbons.

It is known that many operations for the conversion of hydrocarbonmaterials to other hydrocarbon materials of diirering physical and/orchemical properties may be carried out catalytically. Most of these arecarried out by contacting the hydrocarbon, usually in vapor form and athigh temperature, with a contact mass composed of particles whichthemselves have a catalytic efiect or which are impregnated with or actas a support for other catalytic material of a nature appropriate to theresult desired. Such operations may contemplate, for example, theconversion of hydrocarbons of high boiling point to those of lowerboiling point, or the polymerization of light or gaseous hydrocarbons'tohydrocarbons of higher boiling point. Other operations of like natureare catalytic dehydrogenation, hydrogenation, desuliurizing, partialoxidation, and similar conversions of hydrocarbon materials. The methodof operation and apparatus herein described are applicable to all suchconversions. Of these operations, the vapor phase cracking of heavyhydrocarbons to gasoline is 'typical, and this specification willhereinafter discuss such operation as exemplary, without, however,intending to be limited thereby or thereto except by such limits as mayappear in the claims.

Such catalytic processes generally make use of reaction chamberscontaining a fixed body of catalyst or contact mass through which thereaction mixture is passed and in which, after the reaction has sloweddown to an uneconomic point, the contact mass is regenerated in situ.Such processes are not continuous and only attain continuity by theprovision of numerous reaction chambers which are alternatelyplaced onstream and on regeneration. Likewise, it is diflicult to maintainconstant quantity and quality of prodnot without numerous chambers andintricate scheduling because of the progressively decreasing activity ofcatalyst. This same feature, with apparatus limitations, prevents, to adegree, the use of catalyst at a uniform high efllciency level. Most ofthese difficulties may be avoided by the use of a method wherein thecatalyst or contact mass is handled continuously as well. This inventionis specifically diirected to such a process.

This invention has for its object the provision of a process ofhydrocarbon oil conversion wherein a continuously moving stream ofhydrocarbon oil, preferably in the form of vapor heated to conversiontemperature, is contacted with a continuously moving stream of catalystfor the accomplishment of conversion. Important advantages-oi' theprocess contemplated herein are that the catalytic material is used onlyat a high level of efllclency and that it is continuously regeneratedand returned to the conversion step, both operations being conductedunder controlled conditlons. vThe said high level of catalyst efliciencyand constant uniformity in the character of the regenerated catalyst areobtained primarily by controlling the conditions in the regeneratingzone so that the temperature of the catalyst (from which, in the case ofhydrocarbon conversion, carbonaceous deposits must be oxidized orburned) is maintained within the temperature range for eflicientregeneration and at the same time is not permitted to rise above themaximum combustion temperature which would cause substantial heat damageto the catalyst particles.

This temperature control in the regenerator is accomplished by efiectlnga positive thermal exchange between the moving catalyst mass and a heatexchange medium maintained within the moving mass or body of catalyst inindirect heat transfer relation therewith. .In the regeneration ofcatalyst in a hydrocarbon conversion or continuous catalytic crackingoperation, heat is positively extracted from within the moving mass ofcatalyst in the regenerating zone so that the temperature in such zoneis not permitted to rise to a point where the'catalyst particles wouldbe damaged and at the same time the rate of withdrawing such heat issuch that an efficient regencutting or combustion temperature ismaintained. As will hereinafter appear, this positive withdrawal of heat.is effected by a plurality of heat transfer tubes extending into themass of catalyst moving through the zone or chamber in which it isregenerated. These tubes may be either parallel with or transverse tothe direction of catalyst flow. I

Proper apparatus in which the process contemplated herein may be carriedout forms the subject matter of our companion application Serial No.451,859, filed concurrently herewith.

This invention is based upon the principle of carrying out catalyticreactions by flowing a stream of reaction mixture in physical contactwith a flowing stream of catalytic material through a reaction zone inwhich it is in heat exchange relationship with a heat exchange medium ata controlled temperature.

In order that this invention may b understood, reference is made to thedrawings attached to and ;made a part of this specification. In thesedrawings, Figure 1 shows in diagram form a reaction and regenerationapparatus suitable i for use in this process. Figures 2, 3, 4, 5, and 6are concerned with internal details of such chambers, and Figure 7 showsin diagram form a setup of apparatus suitable for the conversion oftion, with a convergent sealed top l3 and a convergent bottom H andfitted with an interior false bottom II, which is perforate, theperforations therein being too small for the passage of catalystparticles but permitting the passage of liquid or gas. Bottom 14 isfitted with pipe i6 and top i3 with pipe [1. At the top of I3 is asealed feeding device l8, which may be a star wheel as shown, anintermittently-operated valve set-up, or other common device of thisnature. Catalyst material introduced through [8 fills the interior oi"shell 8, passes down therethrough, is collected by falsebottom I5 andchute l8 andis removed by a second intermittentlyoperating device, suchas star wheel 20. This arangement effects a continuously moving streamof catalytic materiaI through shell 8.

Reaction mixture-in this case, air for an oxidizing regeneration-may beintroduced through pipe I6, and products of reaction-in this case, fiuegas-may be removed through pipe IT. This eflects a continuously-flowingstream of reaction material in physical contact with thecontinuously-flowing stream of catalytic material in shell 8. The fiowshown is countercurrent. If desired, it may be made concurrent byreversing the functions of i6. and I1. Shell 8 is also internally fittedwith a series of conduits 2| equipped with fins 22 joined to headers 23and 24 through which a heat exchange medium may be passed by means ofpipes 25 and 26. The heat exchange medium may be used to control thetemperature of reaction by extraction of heat 0 from or addition of heatto the material within shell 8, and its flow may be concurrent, counter-,current, or, as later shown, transverse to the direction of flow ofcatalytic material. Thus, in

. the regenerator 8 the temperature of the mass of catalyst underregeneration is closely con- :.:-trolled by effecting a positiveexchange of heat between the catalyst and the heattransfer mexrdiummaintained within the body of catalyst and in indirect heat exchangerelation therewith throughout the conduit system illustrated in Figures1 and 2 as comprising tubes 2]. Shell I8 is similarly fitted andsimilarly operated.

Reaction material, in this case hydrocarbons,

is introduced by 21 and removed-by 28; catalyst movement is controlledby 28 and 38; and heat exchange medium is circulated by pipes 3i and 32.Confined passage 9, maintained relatively full of catalyst by devicesand 29, is fitted with pipes 83 and 8|, by means of which steam may bepassed through the catalyst for purging, thereby preventing the passageof regenerating agent into the conversion chamber. Thus, section 8provides a substantially gas-tight seal between the two chambers. Asimilar purging passage ll connects with the bottom portion of shell l8and is shown as being controlled by devices 38 and 35. The leg orpassage I i is fitted with steam connections 36 -and 31 for purging thecatalyst after the reaction or conversion step so as to preventhydrocarbons other than depositedon the spent catalyst being conductedfrom the bottom of the conversion chamber I8 into regenerating chamber8. From II- the catalyst drops through into boot 38 of elevator [2, bywhich it is elevated and discharged into bin 38a above shell 8. Elevatorl2 may be of the belt and bucket type shown or of any other kindsuitable for the physical properties of th catalytic materials.

It will be apparent from the foregoing that the apparatus shown inFigure 1, wherein there is a controlled gravity fiow of catalyst throughshells or chambers 8 and I 0 into the feed boot 38 of the elevator l2,which returns the spent catalyst to the inlet of shell l0, providesmeans for carrying out the continuous catalytic process contemplatedherein with high thermal efficiency because there is a generalcontinuous movement of catalyst through the system substantiallydirectly from one chamber to the other and the hot catalyst does nothave an opportunity to cool to atmospheric temperature during itsmovement through the circuit. Obviously, arrangements directly from eachzone to the other without permitting it to cool to atmospherictemperature.

Customary devices for the removal of fines and the addition of makeupmay be inserted in the catalyst conveyor system.

Special attention should be given to the arrangement of heat exchangetubes within the shells 8 and I8. These should be arranged so as topermit the passage of catalytic material and reaction materiallongitudinally through the shell in such manner that flowing material isbrought into the desired heat exchange relationship with heat exchangemedium. The conduits may be unfinned, but better results are obtained ifthe external heat transfer surface of the heat exchange tubes isaugmented by the addition of fins thereto. These fins, primarily addedfor heat transfer reasons, may be taken advantage of to assist incontrol of the fiow of catalyst and reaction fluid and contacttherebetween by being disposed so that they, together with the tubes,divide the space within the shell into a series of longitudinal passagesof substantially constant cross-section throughout their length. Thearrangement of these passages should be such that the reaction materialor catalyst moving through the shell comes in eflicient heat exchangerelationship with the heat exchange medium in the tubes. The properdimensions for this condition depend somewhat upon the physical natureof the --catalyst. A commonly-used catalyst for in cubic inches of thepassages containing catalyst and reaction mixture should be numericallyabout one-eighth to twice the surface insquare inches of the heat,transfer surfacein contact I with the passages. Catalyst particles ofdifferent heat-conductivity'or of different packing characteristics, orvariations in' the contemplated intensity of reaction per unit volume ofcatalyst, as well as considerations of heat transfer and pressure dropwill vary the ratio somewhat. The

length of the paths through which the catalyst moves during reaction andregeneration should be relatively great, say from 3 to 15 feet or more.

Figure 2 shows a cross-section of case 8 at the level 2-2 showing howthe preferred longitudinal passages may be formed by equipping each heatexchange tube with two diametricallyopposed, longitudinally-disposedaxial ilns. Figures 3 and 4 show other ways of arriving at the sameresult. The heat transfer tubes need not be arranged parallel to theflow of catalyst but may well be transverse thereto, as shown in Figures5 and 6, wherein transverse tubes 39, carrying fins 40, extend betweenheader boxes ll and 42 in a shell 43, to exercise the same functions ascorresponding parts in shells 8 and I; and, as aforesaid, the spacingand arrangement of the heat exchange tubes or conduits may be varieddepending upon the character of the catalyst and the intensity of thereaction in the chamber or zone.

The heat exchange medium maybe any fluid suitable for the load andtemperature levels encountered, such as gases, liquids of various kinds,molten metals, or alloys, or fused salts. Preferably, it should bepossessed of a low vapor pressure, low viscosity, and high specific heatat temperatures between 600 and 1100" F., noncorrosive to steel, andfluid at about 300-350 F. so that it may be removed from shut-downapparatus by steam heating. Convenient materials for such use aremixtures of the strong alkali salts of the oxy-aclds of nitrogen.

Passages 9 and Ii, used for purging by passing steam through thecatalyst particles, should be so proportioned that a suflicient contactof steam and catalyst particles occurs to remove most of the residualproducts of the preceding reaction.

Reference is now made to Figure '1, which shows an operating set-upappropriate for a conversion of hydrocarbons, such as the vapor phasecracking of petroleum hydrocarbons to form gasoline. A charge oil orcharging stock of the type conventionally used in cracking operations isfed through pipe 44 by pump 45 to a vapor preparation unit 46. Vaporpreparation unit 46 will consist essentially of a heater, for

which purpose any of the usual forms of heater common in the art-say, apipe stillmay be used; to heat and vaporize the charge and heat it toreaction temperature, and, if the charge used is not wholly vaporized atthe reaction temperature, of a vapor separator to remove unvaporizedliquid residue. Vapors from 46 move through pipe 41 into and throughreaction chamber '48 (the same as I, 'Figure 1), and therein theyundergo catalytic reaction. Reaction products pass through pipe 49 toproduct purification and recovery equipment denoted by 50. The equipment50 may be made up of any of the usual fractionation, separation, anddisposal devices currently in common wafer handling products of crackingreactions. If desired, product fractions boiling above the desiredlow-boiling product may be returned to the system for re-treat- I ment,either separately or in admixture with fresh charge. Catalytic materialflowing from 40 is purged in and is elevated by 52, which introducesspent catalyst intothe top of chamber 53. In chamber 53 the spentcatalyst moving downwardly therethrough is regenerated by burnproductsof regeneration being disposed of through pipe 55. The regeneratedcatalyst is purged in 56 and returned to 48. The temperature level ofthe reaction in 48 may be controlled and latent heat of reaction addedthereto by a heat exchange medium introduced through pipe 51 and removedthrough pipe 58. The same heat exchange medium may, in the arrangementshown in Figure '2, be used to control the temperature of regenerationin 53. As aforesaid, the heat exchange medium in the regenerating orreviviflcation zone 53 is used to control the temperature ofregeneration by positively removing heat from within the body of movingcatalyst therein in a manner and at a rate such that the temperature ofthe catalyst does not drop below the temperature for efllcientregeneration or combustion and does not rise above the temperature whichwould cause substantial heat damage to the catalyst material. Forexample, the temperature for regeneration of a spent clay catalyst forcracking hydrocarbons may range from around the cracking temperature(from about 800 F. to about 950 F.) to a peak temperature in theneighborhood of 1050. F. to 1100 F. Care should be exercised in thecontrol of the temperature of the heat exchange medium circulated in theregenerator so that the temperature of the catalyst passing through theregenerator does not rise substantially above 1200 F., or serious damageto a catalyst of this type may result. In the arrangement shown inFigure '7 the heat exchange medium is introduced into heat exchangeconduits in regenerator 53 by pipe 59 and is removed by pipe 60. It iscirculated by pump 6|. The temperature for the several uses may becontrolled by use of various combinations of heat exchangers 82 and 63and by-passes 64, 65, and 86 in a manner obvious to those skilled in theart.

As an example of one operation successfully conducted in such apparatusaccording to the process herein disclosed, coastal gas oil with whichwas admixed steam to the extent of about 10 oil 1 water Yield of 410E.P. gasoline (including ntbutane and heavier in gas) V01. per cent..- 67.4

- Yield of dry gas (lighter than isobutane); Wt. per cent 4. 0 Yield ofcoke do 2.5

' the regeneration chamber (of the same size as the reaction chamber) atthe same rate and was burned with a suflicient volume of air to mainuseof the heat exchange medium at 800 tain above 10 per cent CO2 in theexit flue gas.

The temperature of the reaction was held by and in the same manner thetemperature of the ing with air supplied by blower andpipe 54, the

regeneration was not allowed to rise above 1100 F.

The gasoline produced was of excellent quality, high in anti-knockrating, and the recycle stock was clean, light in color, and of aboutthe same boiling point as the charge. No high-boiling, dirty, liquidcracking tar was produced. The

regenerated catalyst was equal efllciency to new catalyst, no detectabledeterioration in quality being found.

It is to be understood that the specific exby amples and numerical dataherein disclosed are set forth only'as exemplary and that the inven tionis not to be limited thereby or thereto but is to rise to a point whichwould cause substantial heat-damage to the catalyst particles; returningthe regenerated catalyst to said conversion zone;

to'be subject only to those limitations expressed in thefollowingclaims. v

The subject matter of this application has been continuously pendingbefore the United States Patent Oflice since September 4, 1937, thefiling date of our application Serial No. 162,541, the continuity havingbeen effected through the medium of our application Serial No. 361,440,filed October 16, 1940, of which this application is acontinuation-in-part. Therefore, this application is a.continuation-in-part of application Serial No. 162,541.

We claim:

1. A method of conducting a cyclic operation at closely-controlledelevated temperatures for the catalytic conversion of hydrocarbons,which comprises: moving active catalyst particles through a conversionzone; contacting the moving catalyst particles in said conversion zonewith a movingstream of hydrocarbons under high temperature conversionconditions so as to convert the hydrocarbons and thereby cause thecatalyst particles to become spent from deposited carbonaceous material;passing the spent catalyst particles from said conversion zone into ahigh temperature regenerating zone without permitting the catalystparticles to cool to atmospheric temperature; flowing .the spentcatalyst particles throughisaid regenerating zone; contacting the spentcatalyst particles in said regenerating zone with gaseous regeneratingagent (through a regenerating zone; contacting the and substantiallyexcluding oxidizing gases from entering the conversion zone from saidregenerating zone, said heat withdrawal being efl'ected with a heattransfer medium in indirect heat exchange relation with catalyst and ata temperature lower than said combustion temperature.

3. A continuous cyclic method for the catalytic conversion of fluidpetroleum hydrocarbons into high-quality gasoline, which comprises:moving a mass of active catalyst particles through a conversion zone;passing fluid petroleum hydrocarbons through said conversion zone underhigh temperature conversion conditions in contact' with said movingcatalyst mass whereby the said conversion is efiected and the catalystparticles become spent by deposition of carbonaceous material; passingthe spent catalyst particles as a moving mass from said conversion zoneinto and spent catalyst particles with an oxidizing gas in saidregenerating zone, thereby burning off the said carbonaceous depositwith the generation of heat; positively withdrawing heat of combustionfrom within the moving catalyst mass with a fluid heat exchange mediummaintained in indirect heat transfer relation therewith so as tohigh-quality gasoline, which comprises: moving g a mass of activecatalyst particles through a under regenerating conditions, therebyburning deposited carbonaceous material and generating heatofcombustion; controlling the temperature of the catalyst particles soas to maintain eflicient regeneration without substantial heat damage bypositively extracting part of said heat of combus- ,tion with a heattransfer medium in indirect heat exchange relation with catalyst and ata lower temperature than the combustion temperature at a rate such thatthe temperature of the catalyst particles is not permitted to rise to apoint 2. A continuous cyclic method for the catalytic conversion offluid petroleum hydrocarbons into high-quality gasoline, whichcompriseszmoving a mass of active catalyst particles through aconversion zone; passing fluid petroleum hydrocarbons through saidconversion zone under high temperature conversion conditions in contactwith said movingcatalyst mass whereby the said conversion is eflectedand the catalyst particles become spent by deposition of carbonaceousmaterial; passingthe spent catalyst particles as a movingmass from saidconversion zone into and through a regenerating zone; contacting 1 thespent catalyst particles with an oxidizing gas in conversion zone;passing fluid petroleum hydrocarbons through said conversion zone underhigh temperature conversion conditions in contact with said movingcatalyst mass whereby the said conversion is efiected and the catalystparticles become spent by deposition of carbonaceous material; passingthe spent catalyst particles as a moving mass from said conversion zoneinto and through a regenerating zone; contacting the spent catalystparticles with an oxidizing gas in said regenerating zone, therebyburning off the said carbonaceous deposit with the generation of heat;positively withdrawing heat of combustion from within the movingcatalyst mass with a temperature-controlled fluid heat exchange mediummaintained in indirect heat transfer relation therewith so as to preventsubstantial heat damage to the catalyst particles; returning theregenerated catalyst'to said conversion zone; and substantiallyexcluding oxidizing gases from entering the conversion zone.

5. A continuous cyclic method for the catalytic conversion of fluidpetroleum hydrocarbons into high-quality gasoline, which comprises:moving a massof active catalyst particles through a conversion zone;passing fluid petroleum hydrocarbons through said conversion zone underhigh temperature conversion conditions in contact said regeneratingZena-thereby burning off the said carbonaceous deposit with thegeneration of heat; positively withdrawing heat of combustion fromwithin the moving catalyst mass at a rate suchthat the temperature isnot permitted with said moving catalyst mass whereby the said conversionis eflected and the catalyst particles become spent by deposition ofcarbonaceous material; passing the spent catalyst particles as a 7moving mass from said conversion zone into and through a regeneratingzone; contacting the spent catalyst particles with an oxidizing gas insaid regenerating zone, thereby burning oil. the said carbonaceousdeposit with the generation of heat; controlling the temperatureregeneration to prevent substantial heat damage to the catalyst bycirculating a fluid heat exchange medium into indirect heat exchangerelation with the moving catalyst mass and maintaining the temperatureof said heat exchange medium between a minimum temperature for efllcientregeneration and a maximum temperature which would cause substantialheat damage to the catalyst; returning the regenerated catalyst to saidconversion zone; and substantially excluding oxidizing gases fromentering the conversion zone.

6. A continuous cyclic method for the catalytic conversion oi! fluidpetroleum hydrocarbons into high-quality gasoline, which comprises:moving a mass of active catalyst particles through a conversion zone;passing fluid petroleum hydrocarbons through said conversion zone underhigh temperature conversion conditions in contact with said movingcatalyst mass whereby the said conversion is eifected-and the catalystparticles become spent by deposition of carbonaceous material; passingthe spent catalyst particles as a moving mass from said conversion zoneinto and through a regenerating zone; contactingthe spent catalystparticles with an oxidizing gas in said regenerating zone, therebyburning oi! the said carbonaceous deposit with the generation of heat;positively withdrawing heat of combustion from within the movingcatalyst mass with an indirectly contacted heat transfer medium at arate such that the temperature of the catalyst particles is notpermitted to rise to a point where they would be damaged by heat and isnot permitted to drop below an efliclent regenerating temperature; andreturning the regenerated catalyst to said conversion zone. '7. A methodoi conducting a cyclic operation at closely-controlled elevatedtemperatures comprising a catalytic hydrocarbon conversion whereinmoving solid adsorbent catalyst particles areintimately contacted with amoving stream of substantially only vapors, of a hydrocarbon materialand a regeneration reaction wherein the spent catalyst from saidcatalytic reaction is regenerated by intimately contacting the particleswith a gaseous regenerating agent while both are moving, whichcomprises: flowing the active catalyst particles through a conversionzone in intimate contact with a stream of said hydrocarbon vaporsflowing countercurrent thereto under conversion conditions so as toeifect said conversion; withdrawing spent particles from said con:version zone; passing said spent particles into a regeneratingzone'without permitting them to cool to atmospheric temperature; flowingsaid spent particles through said regenerating zone in intimate contactwith a stream of said gaseous regenerating agent flowing countercurrentthereto so as to regenerate the particles; circulating a liquid heatexchange medium within suiliciently close indirect heat exchange withevery catalyst particle in said regenerating zone that the temperatureofall particles while in said regenerating zone may be maintained within asuitable regenerating temperature range while preventing any deleterioustemperature occurring; returning regenerated catalyst particles fromsaid regenerating zone to said conversion zone without permitting themto cool to atmospheric temperature; and preventing said hydrocarbonvapors from passing into said regenerating zone at all times andpreventing said regenerating "agent from passing into said conversionzone at all times.

8. A method of conducting a cyclic operation at closely-controlledelevated temperatures comprising a catalytic hydrocarbon crackingreaction wherein moving solid catalyst particles are intimatelycontacted with a moving stream or substantially only vapors or apetroleum oil to be cracked and a regeneration reaction wherein thespent catalyst from said cracking reaction is regenerated by intimatelycontacting the spent gravitating said spent particles through saidregenerating zone in intimate contact with a stream of said gaseousregenerating agent which rises throughout said regenerating zone so asto regenerate the particles; circulating a molten salt heat exchangemedium, maintained at a temperature between the minimum regeneratingtemperature and the maximum regenerating temperature that does notsubstantially heat-damage said particles.

within close indirect heat exchange with every particle in saidregenerating zone so that heat transfer surface controlled thereby iswithin about one inch of all particles in said regenerating zone,whereby their temperature is maintained within a suitable regeneratingtemperature range while preventing any deleterious tem-' 1 peratureoccurring: returning regenerated particles fronrsaid regenerating zoneto said cracking zone without permitting them to cool to atmospherictemperature; and preventing said petroleum vapors from passing into saidregenerating zone at all times and preventing any substantial amount ofcombustion-supporting gas from passing into said cracking zone at alltimes.

9. A method of conducting a cyclic operation at closely-controlledelevated temperatures for the conversion of hydrocarbons wherein movingsolid catalyst particles are intimately contacted with a moving streamof hydrocarbons to be converted and wherein the spent catalyst from saidconversion reaction is'regenerated by intimately contacting the spentparticles with a gaseous regenerating agent while both are moving, whichcomprises: flowing the active catalyst particles through a conversionzone in intimate contact with a moving stream of hydrocarbon vapors under conversion conditions so as to convert the hydrocarbons and therebycause catalyst particles to become spent from deposited carbonaceousmaterial; purging said spent particles with an inert gaseous mediumtoremove some of the carbonaceous material associated therewith; passingsaid purged spent particles into a regenerating zone without permittingthem to cool to atmospheric temperature; flowing said spent particlesthrough said regenerating zone; intimately contacting said spentparticles in said regenerating zone with a gaseous regenerating agentunder regenerating conditions so as to regenerate said particles;controlling the temperature of the catalyst particles during the periodof catalyst regeneration so as to maintain eflicient regenerationwithout substantial heat-damage to the particles by effecting a positiveheat exchange between the catalyst and a heat exchange medium circulatedwithin the moving catalyst mass in indirect heat transfer relationtherewith; returning regenerated particles from said regeneratin zone tosaid conversion zone without permitting them to cool to atmospherictemperature; and at all times preventing any substantial passage ofhydrocarbon reactant vapors and regenerating agent into saidregenerating zone and said conversion zone, respectively.

10. A method of conducting a cyclic operation at closely-controlledelevated temperatures'come prising a catalytic petroleum conversionreaction wherein moving solid catalyst particles are intimatelycontacted with a moving stream of petroleum oil to be converted and aregeneration reaction wherein the spent catalyst from said conversionreaction is regenerated by intimately con- 7 tacting the spent particleswith a gaseous regen-- crating agent while both are moving, whichcomprises: flowing the active catalyst particles through a conversionzone in intimate contact with a moving stream of said petroleum oilunder' conversion conditions so as to convert the oil and thereby causecatalyst particles to become spent from deposited carbonaceous material;purging said spent particles with an inert gaseous medium to remove someof the carbonaceous material associated therewith; passing said purgedspent particles into a regenerating zone without permitting them to coolto atmospheric temperature; flowing said spent particles through saidregenerating zone in intimate contact with a moving a stream of saidgaseous regenerating agent under regenerating conditions so as toregenerate the particles; controlling the temperature of all particlesin said regenerating zone by circulating a fluid heat exchange medium insaid regenerating zone in indirect heat exchange relation with theparticles therein so as to maintain their temperature at an eflicientregenerating temperature that will not cause substantial heat-damage tothe catalyst particles; returning regenerated particles ing mass ofcatalyst in a conversion zone, whereby the moving mass of catalyst;substantially directly returning the high temperatureregeneratedcatalyst to said conversion zone; preventing any substantialamount of combustion-supporting regenoration gases irom entering theconversion zone Irom said regenerating zone; and fractionating theproducts from the conversion step. 1

, 12. The method of claim 11 which includes the further step of purgingthe hot spent catalyst with a hot inert gas prior to its admission tothe regenerating zone so as to remove adsorbed. oil therefrom, 13. Theprocess of claim 8 wherein the regenerated catalyst particles arepurged'with an inert'gaseous medium in order to remove re- A generationzone gases therefrom before passing said catalyst particles to saidconversion zone.

14. A method of conducting a cyclic operation at closely-controlledelevated temperatures comprising a'catalytic conversion of fluidpetroleum hydrocarbons to high-quality-gasoline wherein moving solidcatalyst particles are intimately contacted with the vapors of saidpetroleum hydrocarbons and a regeneration reaction wherein spentcatalyst particles from said catalytic conversion are regenerated byintimately contacting the particles with a combustion-supporting gawhile both aremoving.

which comprises: flowing the active catalyst particles through aconversion zone; in intimate contact with said petroleum hydrocarbonvapors under conversion conditions so as to eflect said conversion;continuously withdrawing spent particles from sai conversion zone;passing said spent particles stantially, directly to a regeneratingzone; flowing said spent catalysts as a substantially solid column oi.particles through said regenerating zone in intimate contact with saidcombustion-supporting gas flowing countercurrently therethrough so as:to regenerate" the particles by burning of! carbonaceous impurities;circulating a fluid heat exchange mesaid vapors are converted andcarbonaceous material is deposited on said catalyst; introducingcatalyst into said conversion zone and removing catalyst from saidconversion zone without appreciable losses of hydrocarbon vapors wflhsaid catalyst; continuously regenerating said removed catalyst by movingit as a substantially compact mass through a regenerating zone; passingcombustion-supporting gas through the catalyst in the regenerating zoneto burn off the carbonaceous deposit with the generation of heat;positively withdrawing part of the heat of combustion from within themoving mass of catalyst with an indirectly contacted heat transfermedium at such a rate as to prevent the establishment of temperatureconditions which would cause substantial heat damage to the catalystparticles and at the same time the said rate of heat withdrawal beingsuch that an efiicient regeneration temperature is maintained Withindiumwithin sufliciently close indirect heat exchange with everyxcatalystparticle in said regenerating zone that the temperature "of allparticles in said regenerating zone maybe maintained between the minimumcombustion temperature and the maximum combustion temperature that doesnot substantially heat-damage said particles; continuously withdrawingregenerated'catalyst particles from said regenerating zone;returning-said regenerated catslyst particles substantially directly tosaid conversion zone; and preventing-said petroleum vapors from passinginto said regenerating zone at all times-and preventing saidcor'nbustion-sup-- porting gas from passing into said conversion zone atall times.

15. A continuous cyclic method'tor the catalytic conversion ofhydrocarbons which comprises: moving active catalyst particles through aconversion zone while contacting same in said conversion zone with amoving stream of hydrocarbons under high temperature conversionconditions whereby the said conversion-ineffected and the catalystparticles become spent by deposition of carbonaceous'material; passingthe spent catalyst particles from said conversion zone into a hightemperature regenerating zone; moving the spent catalyst particlesthrough said regenerating zone while contacting same with gaseousregenerating agent under regenerating conditions, thereby burningdeposited I carbonaceous material and generating heat of combustion;controlling the temperature of the catalyst particles so as to maintainefficient regeneration without substantial heat damage bypositivelyextracting part of said heat of combustion, with a heat transfer mediumin indirect heat exchange relation with catalyst and at a lowertemperature than the combustion temperature, at a rate such that thetemperature of the catalyst particles is not permitted to rise to apoint where the catalyst will be damaged and is not permitted to. dropbelow an efficient regenerating or combustion temperature; and returningregenerated catalyst particles from said regenerating zone to saidconversion zone.

16. A continuous cyclic method for the catalytic conversion of fluidpetroleum hydrocarbons contact with said moving catalyst mass wherebythe said conversion is effected and the catalyst particles become spentby deposition of carbonaceous material; passing the spent catalystparticles as a moving mass from said conversion zone into and through aregenerating zone; contacting the spent catalyst particles with anoxidizing gas in said regenerating zone, thereby burning off the saidcarbonaceous deposit with generation of heat; positively withdrawingheat of combustion from within the moving catalyst mass at a rate suchthat the temperature is not permitted to rise to a point which wouldcause substantial heat damage to catalyst particles and returningregenerated catalyst to said conversion zone, said heat withdrawal beingeffected into high-quality gasoline, which comprises:

moving a mass of active catalyst particles through a conversion zone;passing fluid petroleum hydrocarbons through said conversion zone underhigh temperature conversion conditions in with a heat transfer medium inindirect heat exchange relation with catalyst particles.

THOMAS P. SIMPSON. JOHN W. PAYNE. JOHN A. CROWLEY, JR.

